Method of Varying a Rest Position and a Length of an Actuation Arc of a Lever in a Hydraulic Disc Brake System

ABSTRACT

A method of varying a rest position and a length of an actuation arc of a lever in a hydraulic disc brake system. The hydraulic disc brake system comprises a master cylinder including a cylinder having a first end and second end and a port communicating with a hydraulic fluid reservoir between the first and the second cylinder ends. A piston is received in the cylinder. The piston has a seal between the cylinder and the piston and the piston is movable within the cylinder by a lever operatively associated therewith to selectively pressurize hydraulic fluid within the cylinder by moving the seal between the port and the second end of the cylinder. The hydraulic disc brake system further comprises a caliper in fluid communication with the master cylinder. The caliper has a pair of brake pads operatively associated with a disc received therebetween. The caliper is actuated by movement of the lever in an actuation arc between a rest position and an engagement point with the pads in engagement with the disc. The length of the actuation arc is variable by movement of the engagement point relative to the rest position along the actuation arc. The method comprises varying a rest position of the lever while simultaneously substantially maintaining the length of the actuation arc as the rest position of the lever is varied and varying the length of the actuation arc while simultaneously substantially maintaining the rest position of the lever and limiting any movement of the piston seal to between the port and the first end of the cylinder as the length of the actuation arc is varied.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.11/552,458, filed Oct. 24, 2006, entitled “Master Cylinder Lever withIndependently Variable Rest Position and Engagement Point,” which is acontinuation of U.S. patent application Ser. No. 10/966,737, filed Oct.15, 2004, entitled “Master Cylinder Lever for a Hydraulic Disc BrakeHaving a Backpack Reservoir,” now U.S. Pat. No. 7,178,646, which is acontinuation of U.S. application Ser. No. 10/316,452, filed Dec. 10,2002, entitled “Master Cylinder Lever for a Hydraulic Disk Brake Havinga Backpack Reservoir”, now abandoned, which application claims priorityfrom U.S. Provisional Patent Application Ser. Nos. 60/344,450, filedDec. 28, 2001; 60/416,130, filed Oct. 4, 2002; and 60/416,698, filedOct. 7, 2002, each entitled “Master Cylinder Lever for Hydraulic DiscBrake.”

TECHNICAL FIELD

The present invention is directed toward an improved master cylinderlever for a hydraulic disc brake, and more particularly to a mastercylinder lever having a variable length of actuation arc and variablerest position that can be varied independently of each other.

SUMMARY OF THE INVENTION

A method of varying a rest position and a length of an actuation arc ofa lever in a hydraulic disc brake system. The hydraulic disc brakesystem comprises a master cylinder including a cylinder having a firstend and second end and a port communicating with a hydraulic fluidreservoir between the first and the second cylinder ends. A piston isreceived in the cylinder. The piston has a seal between the cylinder andthe piston and the piston is movable within the cylinder by a leveroperatively associated therewith to selectively pressurize hydraulicfluid within the cylinder by moving the seal between the port and thesecond end of the cylinder. The hydraulic disc brake system furthercomprises a caliper in fluid communication with the master cylinder. Thecaliper has a pair of brake pads operatively associated with a discreceived therebetween. The caliper is actuated by movement of the leverin an actuation arc between a rest position and an engagement point withthe pads in engagement with the disc. The length of the actuation arc isvariable by movement of the engagement point relative to the restposition along the actuation arc. The method comprises varying a restposition of the lever while simultaneously substantially maintaining thelength of the actuation arc as the rest position of the lever is variedand varying the length of the actuation arc while simultaneouslysubstantially maintaining the rest position of the lever and limitingany movement of the piston seal to between the port and the first end ofthe cylinder as the length of the actuation arc is varied.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a first embodiment of a master cylinderlever for a hydraulic disc brake in accordance with the presentinvention;

FIG. 2 is an exploded view of the backpack reservoir of the mastercylinder lever of FIG. 1;

FIG. 3 is a cross-section of the master cylinder lever of FIG. 1 takenalong line 3-3 of FIG. 1;

FIG. 4 is an exploded view of the piston train of the master cylinderlever of FIG. 1;

FIG. 5 is an exploded perspective view of a socket receptacle spacedfrom a lever handle of the master cylinder lever of FIG. 1;

FIG. 6 is an exploded view of the lever handle attachment assembly ofthe master cylinder lever of FIG. 1;

FIG. 7 is a side elevation view of the master cylinder lever of FIG. 1;

FIG. 8 is a cross-section of the master cylinder lever of FIG. 1 takenalong line 8-8 of FIG. 7, illustrating an adjustable lever pivotassembly;

FIG. 9 is an alternate embodiment of the adjustable lever pivot assemblyof FIG. 8;

FIG. 10 is a perspective view of a second embodiment of a mastercylinder lever for a hydraulic disc brake in accordance with the presentinvention;

FIG. 11 is an exploded view of the backpack reservoir of the mastercylinder lever of FIG. 10;

FIG. 12 is a cross-section of the master cylinder of FIG. 10 taken alongline 12-12 of FIG. 10;

FIG. 13 is an exploded view of the piston train of the master cylinderlever of FIG. 10;

FIG. 14 is a perspective view of the push rod and threaded insert of themaster cylinder lever of FIG. 10;

FIG. 15 is a side elevation view of the master cylinder lever of FIG.10;

FIG. 16 is a schematic representation of the geometry of the lever ofthe present invention;

FIG. 17A is a schematic representation of the geometry of a Brand Blever;

FIG. 17B is a schematic representation of the geometry of a Brand Alever;

FIG. 18 is a schematic representation of the geometry of a Brand Clever;

FIG. 19 is a schematic representation of the geometry of a Brand Dlever;

FIG. 20 is a graph of additional force required from a user's finger (%)versus lever travel from an engagement point for several brands ofhydraulic levers as compared to the lever of the present invention;

FIG. 21 is a graph of a percentage of power to a lever versus levertravel for the lever of the present invention versus several knownlevers;

FIG. 22 is a plot of lever travel versus degrees deviation fromperpendicular of finger force;

FIG. 23 is a cross-section of an alternate embodiment of the lever ofFIG. 12;

FIG. 24 is an exploded view of the lever of FIG. 23; and

FIG. 25 is a cross-section taken along line 25-25 of FIG. 23.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A first embodiment of master cylinder lever assembly 10 is illustratedin a perspective view in FIG. 1. The master cylinder lever assemblyconsists generally of a cylinder housing 12 having a bar clamp 14 at oneend and a lever handle 16 pivotably attached at an opposite end. Alsoseen in FIG. 1 is a reservoir cover 18 which covers a “backpack”reservoir which will be described in greater detail below. Also visiblein FIG. 1 is a contact point adjustment knob 20 which is also describedin greater detail below. The master cylinder housing 12 is hydraulicallyconnected to a slave cylinder which operates a hydraulic caliper (notshown) by hydraulic line 22.

FIG. 2 is an exploded view of the “backpack” reservoir of the mastercylinder lever of FIG. 1. The backpack reservoir consists of a reservoirchamber 28 defined in a rear facing portion of the master cylinderhousing 12. A cylinder wall 30 defining in part the cylinder of themaster cylinder housing 12 extends into the reservoir chamber 28 anddefines in part a first wall 31. Extending through the cylinder wallbetween the reservoir chamber 28 and the master cylinder is a timingport 32 and a compensating port 34. A pair of bosses 36 extend axiallyof the cylinder wall 30 on opposite sides of the timing and compensatingport 32, 34. A side wall 37 extends from the first wall. A diaphragm 38made of an elastomeric material such as silicon rubber is made tooverlay the side wall 37 and cover the reservoir chamber 28. Thus, thefirst wall 31, the side wall 37 and the diaphragm 38 define thereservoir chamber 28. The diaphragm 38 has an expansion protrusion 40extending therefrom opposite the reservoir chamber. A reservoir frame 42is configured to receive the periphery of the diaphragm 38 to maintain atight seal between the diaphragm 38 and the reservoir chamber 28. Thisseal is promoted and the assembled relationship maintained by fourscrews 44 received in corner holes of the reservoir frame 42 anddiaphragm 38 and threadably engaged with corresponding holes in themaster cylinder housing 12. A vanity cover 46 snap fits over thediaphragm and frame to both provide an aesthetic appearance and toprotect the diaphragm 38.

Locating the timing and compensating ports 32, 34 on the cylinder wall30 as illustrated in FIG. 2 essentially eliminates the possibility ofair entering either of the timing or compensating ports regardless ofthe position of the master cylinder. As should be apparent to oneskilled in the art, this is because air will always rise and the curvedsurface of the cylinder wall always cause air bubbles to be deflectedaway from the timing and compensating ports regardless of the positionof the master cylinder. While in the preferred embodiment illustratedherein, the cylinder wall 30 is truly cylindrical, it could also haveother configurations such as a triangular configuration with the portslocated at the apex of the triangle which would have the same affect ofpreventing air bubbles from collecting in the vicinity of the timing orcompensating ports. Any other profile of the cylinder wall or locationof the ports on the cylinder wall which prevents collecting of airbubbles in the vicinity of the timing and compensating ports isconsidered to be within the scope of the invention. The bosses 36 areprovided to prevent the diaphragm 38 from covering and inadvertentlysealing the compensation or timing ports as hydraulic fluid is drawninto the compensating and timing ports. As would be apparent to thoseskilled in the art, the bosses 36 could be replaced with similarlypositioned posts or the like or other extensions to perform the samefunction of keeping the diaphragm spaced from the ports and such otherconfigurations may have an additional advantage of minimizing thepotential of air bubbles collecting in the vicinity of the ports. Thisstructure facilitates a single lever being used on either a right orleft portion of a handle bar without risk of bubbles entering thehydraulic fluid line.

FIG. 3, a cross-section of the master cylinder, illustrates the pistontrain 49 operatively associated with the cylinder 50 of the mastercylinder housing 12. The cylinder 50 has a first end 51 and a second end52. FIG. 4 illustrates the piston train 49 in an exploded view and thesame reference numbers will be used to identify like elements in FIG. 3and FIG. 4.

The piston train consists of a piston 54 received in the cylinder 50having an annular cup or umbrella seal 56 abutting an internal portionof the piston 54. A compression spring 60 biases the piston 54 towardthe first or open end of the cylinder 51. An “O” ring 62 forms a lowerseal on the piston and is received within an annular recess in thepiston. A hex spacer 64 has leading protrusion 66 with an annular detentthat is snap fit into a corresponding female receptacle 68 in a trailingend of the piston 54. This snap fit allows for relative rotationalmovement between the piston and the hex spacer 64. The hex spacer 64 isin turn received in a hex hole 70 of contact point adjustment knob 20.The knob 20 also has a leading externally threaded extension 72 whichthreadably engages a countersink 74 concentric with and external of thecylinder 50. A male pushrod 76 having an externally threaded shaft 78 atits first end and a ball head 80 at its second end with posts 82extending in opposite directions therefrom is snap fit received in aslotted socket 84 on an end opposite the protrusion 66 of the hex spacer64 with the post 82 received in the slots 86, as best seen in FIG. 3.The male pushrod 76 in turn is threadably engaged with a female pushrod86 having an internally threaded cylinder 88, again best viewed in FIG.3. The female pushrod also includes a ball head 90 having oppositelyextending posts 92. A socket insert 94 has a leading ball socket 96 withopposite slots 98 for snap fit receiving the ball head 90 with the posts92 received in the corresponding slots 98. The socket insert 94 alsoincludes locking posts 100. Referring to FIG. 5, these locking posts arereceived within a keyed orifice 102 in the lever handle 16 and thenrotated 90° to lock the posts 100 in the annular slot 104. Referringback to FIG. 3, a dust cover 106, which is preferably elastomeric, isengaged in an annular slot 108 of the knob 20 with a nipple endreceiving the female pushrod 86 as shown.

The basic operation of the master cylinder is well understood by thoseskilled in the art. Referring to FIG. 3, pivoting the lever handle 16upward from a rest position toward the cylinder housing causes thepiston train 50 to drive the piston upward within the cylinder. As thepiston moves upward in the cylinder the cup or umbrella seal 56 coversthe timing port 32 which pressurizes the fluid within the hydraulic line22 at the second end of the cylinder and which in turn actuates a slavecylinder within a hydraulically coupled brake caliper (not shown). Whenthe lever handle 16 is released, the compression spring 60 biases thepiston toward the first end of the cylinder to reassume the positionshown in FIG. 3. The distance between the cup seal 56 and the timingport 32 is referred to as the “dead-band.” During the part of leveractuation where the cup seal is between the timing port 32 and the firstend of the cylinder, fluid in the reservoir between the seal and thetiming port returns to the reservoir chamber 30, perhaps causingexpansion of the expansion protrusion 40 of the diaphragm 38. Duringthis part of lever actuation, the second end of the cylinder cannot bepressurized. It is highly desirable to be able to adjust the length ofthe dead-band in accordance with user preferences. Rotation of thecontact point adjustment knob 20 in a first direction allows for thedead-band to be taken up and reduced and rotation in a second directionincreases the dead-band. In FIG. 3 a maximum dead-band is shown becausethe knob is almost fully threaded from the countersink 74. Threading theknob into the countersink causes the piston to move upward, thusreducing the dead-band. Obviously, the hex engagement between the hexspacer 64 and the knob 20 causes the hex spacer to rotate with the knob.However, the snap fit between the protrusion 66 and the femalereceptacle 68 of the piston prevents the piston from rotating relativeto the knob, minimizing impairment of the seals.

One highly advantageous aspect of this design is that as the knob isscrewed inward in the first direction, the male pushrod rotates axiallybecause of engagement between the posts 82 and the hex spacer. Thethreads between the male pushrod 76 and the female pushrod 86 areconfigured to cause the male pushrod to extend further from the femalepushrod as a result of this axial rotation in the first direction. Therespective threads of the knob and the pushrods are designed such thatthe net result is that the lever handle does not move relative to thehousing as the knob is turned. This feature has the important advantageof maintaining a preselected start position of the lever resulting reachbetween the lever and the handlebar as the dead-band of the mastercylinder is adjusted.

In the event a user wishes to adjust the reach of the lever (that is,the distance between a handle bar and the lever at the rest position),this can be done independently of the dead-band adjustment by pivotingthe handle away from the caliper housing to disengage the snap fitbetween the ball head 90 and the ball socket 96 of the socket insert 94.Once disengaged, the female pushrod 86 maybe rotated about its axis toextend or retract the female pushrod relative to the male pushrod toadjust the reach as desired. While the current embodiment may allowadjustment in 180° increments, other configurations allowing smallerincrements of variation or perhaps event infinite variation of the leverreach are within the possession of those skilled in the art and withinthe scope of the invention.

FIG. 6 is an exploded view of the lever pivot assembly 110 of the firstembodiment of the master cylinder lever of FIG. 1. The lever pivotassembly 110 consists of an axial bore 112 about which the lever handle16 pivots. A threaded hole 114 perpendicularly intersects the bore 112.A slotted bushing 116 (preferably made of plastic) which is part of abushing plate 118 extends into each end of the bore 112. A female bolt120 is received through one slotted bushing while a male bolt 122 isreceived through the other slotted bushing so that they threadablyengage within the bore 112. As perhaps best seen in FIG. 8, the slottedbushings 116 each have annular camming tapers 124 between smaller andlarger diameter portions of the bushing. A head of the female bolt 120similarly has a camming taper which mates with the camming taper 124 ofthe bushing. Likewise, the male bolt has a cammed surface which mateswith a corresponding cammed surface of its corresponding bushing.Referring to FIG. 8, as should be apparent to one skilled in the art, asthe male bolt is threaded into the female bolt in the assembledconfiguration, the cam relationship causes the bushings to expandradially as the bolts are drawn axially together. This causes any “slop”in the pivotal connection between the lever handle and the caliperhousing to be taken up. A lock screw 130 is threadably received in thethreaded hole 114 and, as illustrated in FIG. 8, can be threadablyinserted in the hole to lock the male and female bolts in their selectposition. As the pivot wears the lock screw 130 can be backed off andthe female and male bolts more tightly threadably engaged to pickup anyslop.

FIG. 9 is an alternate embodiment of the adjustable lever pivot assembly110′. This embodiment differs in that the male bolt has a portion havingan outer diameter equivalent to the outer diameter of the female boltillustrated at 132 and the female bolt does not extend as far axially asthe embodiment illustrated in FIG. 8. A gap 134 is provided between thisenlarged diameter 132 of the male bolt 122′ and the female bolt 120′. Inthis embodiment, the lock screw 130 directly engages each of the malebolt 122 and the female bolt 120 which may provide more secure lockingalthough it may not provide as much axial adjustment from either end ofthe lever.

FIG. 10 is a second embodiment of a master cylinder lever for a bicyclehydraulic disc brake 200 of the present invention. The second embodimentof the master cylinder lever assembly 200 consists of a cylinder housing202 having a bar clamp 204 at one end and lever handle 206 pivotablyattached to the housing at an opposite end. A reservoir housing 208covers a hydraulic fluid reservoir 210 which will be discussed ingreater detail below. Also visible in FIG. 10 is a worm knob 212 used toadjust the lever dead-band in a manner that will be discussed in greaterdetail below. The master cylinder housing 202 is hydraulically connectedto a slave cylinder which operates a hydraulic caliper (not shown) byhydraulic line 214.

FIG. 11 is an exploded view of a “backpack” reservoir of the mastercylinder lever of FIG. 10. The backpack reservoir of FIG. 11 isidentical in its configuration to the backpack reservoir of FIG. 2except it is oriented substantially horizontally within the leverhousing whereas the backpack reservoir of the first embodiment of themaster cylinder lever of FIG. 1 is oriented vertically. The samereference numbers are used to describe like elements and the detaileddescription of these elements is provided above with reference to FIG.2.

FIG. 12 is a cross-section the master cylinder lever assembly of FIG. 10taken along line 12-12 of FIG. 10. FIG. 12 illustrates a piston train220 received within a cylinder 222 defined within the hydraulic cylinderhousing 202. The cylinder 222 has a first end 224 and a second end 226.A threaded countersink 225 in the housing 202 abuts the second end 226of the cylinder 222, coaxial with a longitudinal axis of the cylinder.FIG. 13 illustrates the piston train 220 in an exploded view and thesame reference numbers will be used to identify like elements in FIGS.12 and 13.

The piston train 220 consists of a piston 228 within the cylinder 222.The piston 228 has a first annular cup or umbrella seal 230 near aleading end and a second annular cup or umbrella seal 232 near atrailing end. A push rod 234 has a threaded portion 236 at a first endand a head 238 at a leading second end. A leading portion of the head238 defines a ball surface which is received in a corresponding cupsurface 240 in a trailing end of the piston 220. The threaded portion236 of the push rod 234 is threadably engaged with the lever handle 206in a manner that will be discussed in greater detail below. A hexorifice 241 is defined in the second end of the push rod and sized tofit an appropriate Allen wrench. A plurality of radial ribs 242 extendaxially from a rear surface of the head 238 opposite the ball surface(see FIG. 14). An externally threaded insert 244 has an externallythreaded leading axial portion 246 and a trailing axial portion 248having radially inclined gear teeth which are best viewed in FIGS. 13and 14. The threaded insert 244 further has an axial bore 250 havingconical side walls. The bore 250 opens at the first end to an annularpocket 252 having axially extending teeth 254 configured to mate withthe radial ribs 242 which extend axially from the rear surface of thehead 238 (See FIG. 14). Externally threaded insert 424 further includesa rearward facing pocket 256 receiving an elastomeric annular wipe seal257 having a nipple which forms a seal with the push rod 234.

A worm 258 is received in the housing along an axis transverse an axisof the cylinder. The worm 258 has a threaded shaft 259 and a worm knob212. The threads 259 of the threaded shaft threadably engage theradially inclined teeth 248 of the externally threaded insert 244. AC-clamp (not shown) or the like secures the worm 258 within thetransverse bore in the housing by engaging an annular groove 261 in thedistal end of the threaded shaft 259.

A coil spring 262 resides between a second end 226 of the cylinder and aleading end of the piston 228 to bias the piston toward the first end224. The coil spring also compresses the radial ribs 242 of the push rodhead 238 into mated engagement with the axially extending teeth 254 ofthe threaded insert 244 so the push rod 234 rotates axially as thethreaded insert is rotated.

The lever handle 206 may be pivotably attached to the housing by leverpivot assembly described above with reference to FIGS. 6 and 8.Alternatively, a conventional pivot coupling may be used. Spaced fromthe lever pivot assembly 110, is a bore 264 in the lever along an axisparallel to the axis of the lever pivot assembly and transverse the axisof the cylinder 222. A cross dowel 266 is received in the bore 264. Thecross dowel 266 includes a threaded bore 268 transverse the dowel axis.Referring to FIG. 12, this threaded bore 268 threadably receives thethreaded portion 236 at the first end of the push rod 234.

The basic operation of the master cylinder lever 200 of FIG. 12 issimilar to that of the first embodiment of the master cylinder lever 10discussed above with reference to FIG. 3. The lever handle 206 is shownat a rest position in FIG. 12. As the lever is pivoted upward toward thebar clamp 204 and toward a fully actuated position, the push rod 234 isdriven forward which in turn causes the piston 228 to move toward thesecond end 226 of the cylinder 222. As the piston 228 moves toward thesecond end 226 of the cylinder 222 the leading cup or umbrella seal 230covers the timing port 32 which prevents flow of fluid from the cylinderinto the reservoir and causes build up of pressure in the second end ofthe hydraulic fluid cylinder which in turn pressurizes fluid within thehydraulic fluid line 22 and which in turn actuates a slave cylinderwithin a hydraulically coupled brake caliper (not shown). When the leverhandle 16 is released, the compressing spring 262 biases the piston 228toward the first end 224 of the cylinder to reassume the position shownin FIG. 12. Pivoting of the push rod 234 about the head 238 by pivotingof the lever handle 206 is accommodated by the conical side walls of theaxial base 250.

The distance between the cup seal 230 and the timing port 32 is referredto as the dead-band. As described above with reference to FIG. 3, duringthe part of lever actuation where the cup seal is between the timingport 32 and the first end of the cylinder, fluid in the reservoirbetween the seal and the timing port returns to the reservoir 30. Duringthis part of lever actuation, the second end of the cylinder cannot bepressurized. To adjust the length of dead-band, the piston can beadvanced in the cylinder by rotating the knob 212 in a first directionwhich in turn causes rotation of the threaded insert to threadablyadvance the threaded insert within the threaded countersink 225 alongthe cylinder axis, thereby advancing the piston toward the second end ofthe cylinder. Turning of the knob 212 in a second direction reverses thedirection of the threaded insert to increase the dead-band. The ball andsocket connection between the cup 240 at the trailing end of the pistonand the ball at the leading end of the head 238 of the push rod 234prevents the piston from rotating relative to the threaded insert whichhelps maintain the integrity of the seals.

The second embodiment of the hydraulic cylinder lever of FIG. 12 alsoincludes a structure for compensating for movement of the push rodduring dead-band adjustment to maintain the lever 206 in a select restposition. The threads between the threaded portion 236 of the push rodand the threaded bore 268 of the cross dowel 266 are configured tocounteract pivoting of the handle that would otherwise occur about thelever pivot assembly 110 when the push rod 234 is moved by movement ofthe threaded insert 244. In other words, as the threaded insert 244 isadvanced toward the second end of the cylinder, which necessarily causesthe advancement of the push rod 234 toward the second end of thecylinder and which would normally cause the lever handle 206 to pivotupward, the threaded engagement between the second end of the push rodand the cross dowel tends to move the lever handle 206 downward in anamount that corresponds to what would be the upward movement so as tomaintain the lever handle 206 at a select start position.

In the event a user wishes to adjust the reach of the lever, this can bedone independently of the dead-band adjustment. Insertion of an Allenwrench into the hex orifice 241 allows for axial rotation of the pushrod 234. However, the worm connection between the threaded insert 244and the worm 258 prevents rotation of the threaded insert 244 by thepush rod 234. Because the threaded insert 244 is relatively fixedagainst rotation, turning of the push rod 234 causes disengagementbetween the radially extending ribs 242 of the head 238 and thecomplimentary axially extending teeth 254 in the externally threadedinsert against the bias of the spring 262 and allows for pivotalmovement of the lever handle 206 up or down in accordance with userpreferences to provide a select reach. The teeth 254 and ribs 242preferably have inclined, mating surfaces which define rampsfacilitating this disengagement against the force of the bias of thespring 262. Disengagement can be aided by pushing axially on the Allenwrench against the spring bias as the push rod 234 is rotated.

In a highly preferred embodiment, the axis of the threaded bore in thecross dowel is provided to not intersect with the cross dowel axis. Thishas the effect of locking the push rod in place relative to the crossdowel when a load is placed on the lever handle 206 so as to preventrelative rotation between the push rod 234 and the cross dowel 236. Thisfeature thereby prevents inadvertent variation of the lever reach duringlever actuation. An off-set of between 0.01-0.04 inches between the axeshas been found to be sufficient.

FIG. 15 is a side elevation view of a master cylinder lever of FIG. 10.This figure is used to illustrate an embodiment of a lever geometrywhich has been found to provide significant advantages in leveroperation. The bar clamp 204 is designed to receive a handle bar 280along a clamp axis 282. The lever handle 206 is pivotably connected bylever pivot assembly 110 about a pivot axis 284. In a highly preferredembodiment, the pivot axis is 39 mm from the clamp axis. The leverhandle 206 defines a finger receptacle 286 configured to receive atleast one finger of a user. In the embodiment illustrated in FIG. 15,the finger receptacle 286 is configured to receive two fingers of a userand effective finger force point 288 is defined by approximately thecenter of a typical user's two fingers. For the purpose of thisapplication and the charts and calculations herein, the location of thefinger force point is deemed to be 30.0 mm from the end of the leverwhen based on an estimate of an average user's finger size. A selectfinger actuation path is defined by arrow 290, and extends from theeffective finger force point 288 at an “engagement point” of the lever.As used herein, the “engagement point” means a point along the arc oflever actuation where the pads of a caliper operatively associated withthe master cylinder lever begin compressing a disc therebetween. Inother words, a point where the lever handle drives the piston trainagainst operative fluid resistance. The select ideal finger actuationpath 290 is a design criteria intended to estimate a typical finger pathof a user of the brake in typical operating conditions. Based uponobservations of users, the select ideal finger actuation path is at anangle θ 90° or greater. In FIG. 15 the angle θ is 96°, a best estimateof a typical average finger path. Actual finger paths may range from90°-108°, or even greater than 108°. An arc 292 is defined by movementof the effective force point 288 as a lever is actuated between theengagement point position shown in FIG. 15 and a fully actuated positionwith the effective force point 288 at point 288′ in FIG. 15.

In one embodiment of the invention illustrated in FIG. 15, the pivotaxis 284 is preferably spaced from the clamp axis 282 a distance suchthat a chord between the points 288 and 288′ of the arc 292substantially corresponds to the select ideal finger actuation path 290.In this manner, a user experiences a mechanical advantage resulting fromhandle actuation that does not substantially decrease as the handle ispivoted between the at rest position and the fully actuated position.The angle of the chord between the point 288 and 288′ could actually beslightly less than the angle θ, but should be no less than 6° less thanthe angle θ so as to prevent an unacceptable loss of mechanicaladvantage.

The desired chord defined by the arc between the rest position and thefully actuated position of the effective finger force point is able tomeet the criteria of substantially corresponding to an ideal fingeractuation path in the range of greater than 96° if the pivot axis 284can be brought close enough to the clamp axis 282. In the embodimentillustrated in FIG. 15, this geometry is facilitated by locating thereservoir 208 and the cylinder 222 of the master cylinder lever housinggenerally parallel to the clamp axis 282, and the pivot 39 mm from theclamp axis. Where the master cylinder is aligned vertically as with thefirst embodiment illustrated in FIGS. 1-5, it would be very difficult tomeet these design criteria because the cylinder and reservoir residebetween the pivot axis 284 and the clamp axis 282. This is illustratedin FIG. 7. Here, the arc 292′ defined by pivotal movement of theeffective finger force point 288 from the engagement point to the fullyactuated position 288′ defines a chord 294′ that forms an angle lessthan 90° from the clamp axis 282. However, the angle θ of the selectideal finger actuation path is greater than 90°, again preferablygreater than 96°. As a result, a user would sustain a significant lossof mechanical advantage when trying to actuate the lever handle 206along the select ideal finger actuation path 290′.

FIGS. 16-19 illustrate the geometry of a highly preferred embodiment ofthe present invention as compared to representative hydraulic mastercylinder levers on the market in 2002. FIG. 17A is a Brand B levergeometry. FIG. 17B is a Brand A lever geometry. FIG. 18 is a Brand Clever geometry. FIG. 19 is a lever geometry of a Brand D hydraulic brakelever.

Beginning with FIG. 16, in a highly preferred embodiment of the presentinvention, the pivot axis 284 is 39 mm from the clamp axis 282. For thepurpose of this analysis, it is assumed that the engagement point is 50mm from the clamp axis 282, and is illustrated by the line 300. Theapplication of braking force from the engagement point to the conclusionof the lever movement is assumed to be 10 mm and is represented by thefull actuation line 302. Finally, for the purpose of this analysis, theassumed ideal finger actuation pad 290 is an angle θ 96° from the clampaxis. The effective finger force point 288 is 30 mm from the bar end.The arc 304 represents the effective finger force point travel as thelever is actuated. A chord drawn between the engagement line where theeffective finger force point is located at the beginning of brakeactuation and the point that the full actuation line 302 intersects thearc 304 is at 96°, equal to the ideal finger path angle θ. This providesfor a minimal loss of mechanical advantage as the lever is actuated.

In FIG. 17A the Brand B lever has a pivot axis 284 53 mm from the clampaxis 282. Again, assuming an engagement point 300 beginning 50 mm fromthe clamp axis and a full actuation line 302, 10 mm from the engagementpoint, it can be observed that the arc 304 of travel of the effectivefinger force point 208 deviates inwardly from the ideal finger path 290.The same is true in FIG. 17B, where the Brand A lever pivot axis is 50mm from the clamp axis 282. As will be illustrated in the figuresdiscussed below, this results in an increasing loss of mechanicaladvantage over the lever stroke.

FIGS. 18 and 19 represent the geometry of the Brand C and Brand Dhydraulic brake levers respectively. Like numbers are used to identifylike elements of these figures. Brand C, with the pivot axis located 63mm from the clamp axis has a more pronounced deviation of the arc 304from the ideal finger path 209 and thus, as will be illustrated below,has even a greater loss of mechanical advantage than the Brand B lever.Finally, the Brand D levers, with a pivot point 65 mm from the clampaxis, produces an even greater loss of mechanical advantage.

FIGS. 20 and 21 illustrate the respective mechanical advantage of thelever geometry of the present invention, designated as Avid, and theBrands A-D illustrated schematically above. Referring first to FIG. 20,the geometry of Brands A-D levers each will result in applying anadditional amount of force to the lever along the ideal finger path overthe course of the lever actuation. With respect to the Avid lever of thepresent invention, it can be seen that the geometry actually produces anincreasing mechanical advantage over the first 5 mm of lever travel andthen a slight decrease of mechanical advantage (less than 1%) over thefinal 5 mm of lever travel. Over the full range of lever travel, a netloss of mechanical advantage is zero.

FIG. 21 is essentially the inverse of FIG. 20. It illustrates that thegeometries of the Brand A-D levers result in a loss of power over theactuation stroke. Again, the Avid lever of the present inventionactually provides improved power through the first 5 mm with slightlydecreasing power over the final 5 mm of travel and no change in the netamount of power applied to the lever between the engagement point andfull actuation of the lever.

FIG. 22 illustrates where the loss of power comes from by comparing howfar from perpendicular to the clamp axis the finger force is over thelever actuation stroke. For the geometry of the present invention (theAvid lever), the force begins 5 mm off, goes to perpendicular at aboutthe center of the stroke and then returns to 5 mm off at the conclusionof the stroke. For Brands A-D, a significant deviation fromperpendicular is present at the beginning of the stoke and increasesfrom there.

As is apparent, the Avid lever geometry provides an increasing range ofmechanical advantage over at least a portion of the lever actuation. Inits broadest sense, the present invention can be characterized as theselection of a lever geometry having a pivot axis of 50 mm or less thatis always equal to or closer to the clamp axis than the engagementpoint. This geometry produces a lever having an increasing mechanicaladvantage over at least a portion of the actuation stroke but does notencompass the geometry of the Brand A lever which is believed to be thelever having the pivot axis the closest to the clamp axis known in theart.

FIG. 23 is a cross-section of an alternate embodiment of the drive trainof a master cylinder. The piston and cylinder of the embodiment of FIG.23 is essentially identical to that of the embodiment of FIG. 12, andlike reference numbers followed by a prime (′) are used for likeelements and described above in detail with respect to FIG. 12. Theprimary difference in the structures begins to the right of the surface240′ in the trailing end of the piston 220, which in FIG. 23 is flat asopposed to a cup surface.

The embodiment of FIG. 23 has push rod 400 having a threaded portion 402at a first end and head 404 at a second end. The head 404 has a borereceiving a pin 406 transverse the axis of the pushrod 400. The head 404is received in a socket 408 within a piston coupling 410 having aleading flat surface 412 abutting the cup 240′. Referring to FIG. 24,the piston coupling 410 has axial slots 414 which receive the pins 406to allow axial movement of the head 404 within the piston coupling 410,but prevent axial rotation of the push rod 400 relative to the pistoncoupling 410. The threaded portion 402 of the pushrod is threadablyengaged with the lever handle 206′ in the same manner discussed abovewith respect to the embodiment of FIG. 12, including the off-centercoupling with the cross-dowel. The piston coupling 410 has an annularflange 416 with sinusoidal florets 418 extending radially therefrom. Anexternally threaded insert 430 has an externally threaded leading axialportion 432 and a trailing axial portion 434 having radially inclinedgear teeth which are best viewed in FIG. 24. Threaded insert 430 furtherhas an axial bore 436 having sinusoidal florets 438 configured to matewith the sinusoidal florets 418 of the piston coupling 410. Anelastomeric annular wipe seal 440 having a nipple 442 received in anannular groove 444 of the push rod 400 abuts the threaded insert 430.

The lever of FIG. 23 also includes a worm 258′ essentially identical tothat of the embodiment discuss above with respect to FIG. 12 and whichwill not be re-described here. Likewise, the pivot assembly 446 issimilar to that described with reference to FIG. 12.

The basic operation of the master cylinder of FIG. 23 is identical tothat of the master cylinder lever 200 of FIG. 12 and this descriptionwill not be repeated. The embodiment of FIG. 23 shares the features ofindependent reach adjustment and a dead-band adjustment that compensatesfor and prevents change of the reach adjustment during dead-bandadjustment and is not re-described here. The reach adjustment differsslightly from the embodiment discussed above with respect to FIG. 12. Inthe embodiment of FIG. 23, insertion of an Allen wrench into a hexsocket 448 allows for reach adjustment. Axial rotation of the push rodby an Allen wrench will cause indexed axial rotation of the pistoncoupling 410 relative to the threaded insert 430. The threaded insert430 is prevented from axial rotation by the worm 258′. The axial slots414 allow disengagement and relative movement of the florets and axialrotation of the piston coupling 410 relative to the push rod 400 isprevented by the pins 406 received in the slots 414. In a preferredembodiment, each indexed rotation of the push rod causes a uniformmovement of the lever end relative to the clamp axis (e.g., 1 mm). Themating florets are illustrated in FIG. 25 in a cross-section taken alongline 25-25 of FIG. 23.

The embodiment of FIG. 23 also includes a feature to protect the pistontrain in the event of an accident causing movement of the lever handle206 away from the clamp axis. In such an event, the head 404 of the pushrod can axially disengage from the socket 408 of the piston coupling ina direction to the right. Once a user recovers from such a mishap, thelever can be simply returned to its normal rest position which willcause the head 404 to pop back into the socket 408.

1. A method of varying a rest position and a length of an actuation arcof a lever in a hydraulic disc brake system, the hydraulic disc brakesystem comprising a master cylinder including a cylinder having a firstend and second end and a port communicating with a hydraulic fluidreservoir between the first and the second cylinder ends, a pistonreceived in the cylinder, the piston having a seal between the cylinderand the piston, the piston being movable within the cylinder by a leveroperatively associated therewith to selectively pressurize hydraulicfluid within the cylinder by moving the seal between the port and thesecond end of the cylinder, the hydraulic disc brake system furthercomprising a caliper in fluid communication with the master cylinder,the caliper having a pair of brake pads operatively associated with adisc received therebetween, the caliper being actuated by movement ofthe lever in an actuation arc between a rest position and an engagementpoint with the pads in engagement with the disc, the length of theactuation arc being variable by movement of the engagement pointrelative to the rest position along the actuation arc, the methodcomprising: varying a rest position of the lever while simultaneouslysubstantially maintaining the length of the actuation arc as the restposition of the lever is varied; and varying the length of the actuationarc while simultaneously substantially maintaining the rest position ofthe lever and limiting any movement of the piston seal to between theport and the first end of the cylinder as the length of the actuationarc is varied.